Method for ventilating a seat

ABSTRACT

The present invention relates to a ventilated seat having an insert with a seat portion, and having a flow control layer with first and second ports, a spacer having an inlay and a main portion, and a first fluid barrier where the inlay is substantially isolated from the main portion by a fluid-tight boundary. The present invention also relates to a ventilated seat having an insert with a seat portion and having a first flow control layer with at least one port, a first and a second spacer, and a fluid barrier comprising at least one port. The present invention also relates to a ventilated seat with an insert having a seat portion and having a flow control layer with a port and a plurality of flow holes in the seat portion, a spacer, a fluid barrier and at least one conduit with a plurality of flow holes located adjacent to the seat portion of the flow control layer. The seat also may include a fan in fluid communication with the spacer and a fluid conditioning device. The present invention also relates to methods of ventilating a seat. The method includes providing a thermoelectric device (TED) and conditioning air with the TED to provide heating or cooling and communicating that conditioned air through an insert with either pushing or pulling the condition air through the insert.

CLAIM OF PRIORITY

The present application claims the benefit of U.S. provisionalapplications Ser. No. 60/505,806, filed Sep. 25, 2003 and Ser. No.60/525,959, filed on Dec. 1, 2003.

FIELD OF THE INVENTION

The present invention relates generally to an insert and system forproviding heating, cooling, ventilation or a combination thereof to aseat and more particularly to an insert and system for an automotivevehicle.

BACKGROUND OF THE INVENTION

For many years the transportation industry has been concerned withdesigning seats for automotive vehicles that provide added comfort tooccupants in the seats. Various innovations in providing seating comfortare discussed in U.S. Pat. Nos. 6,064,037; 5,921,314; 5,403,065;6,048,024 and 6,003,950, all of which are expressly incorporated hereinby reference. In addition, other innovations in providing seatingcomfort are discussed in U.S. patent application Ser. No. 09/619,171,filed Jul. 19, 2000, titled “Ventilated Seat Having a Pad Assembly and aDistribution Device”; U.S. Publication No. 2002/0096931, filed Jan. 5,2001, titled “Ventilated Seat”; U.S. Pat. No. 6,629,724, issued Oct. 7,2003, titled “Portable Ventilated Seat”; U.S. patent application Ser.No. 10/434,890, filed May 9, 2003, titled “Automotive Vehicle SeatInsert”; U.S. patent application Ser. No. 10/463,052, filed Jun. 17,2003, titled “Automotive Vehicle Seating Comfort System”; and U.S.patent application Ser. No. 10/681,555, filed Oct. 8, 2003, titled“Automotive Vehicle Seating Comfort System”, each of which are expresslyincorporated herein by reference for all purposes.

In the interest of continuing such innovation, the present inventionprovides an improved insert and system for a seat, which are preferablysuitable for employment within or as part of an automotive vehicle seatand which assist in providing comfort control to an occupant in theseat.

SUMMARY OF THE INVENTION

The present invention relates to a ventilated seat having an insert witha seat portion, and having a flow control layer with first and secondports, a spacer having an inlay and a main portion, and a first fluidbarrier where the inlay is substantially isolated from the main portionby a fluid-tight boundary. The present invention also relates to aventilated seat having an insert with a seat portion and having a firstflow control layer with at least one port, a first and a second spacer,and a fluid barrier comprising at least one port. The present inventionalso relates to a ventilated seat with an insert having a seat portionand having a flow control layer with a port and a plurality of flowholes in the seat portion, a spacer, a fluid barrier and at least oneconduit with a plurality of flow holes located adjacent to the seatportion of the flow control layer. The seat also may include a fan influid communication with the spacer and a fluid conditioning device.

The present invention also relates to methods of ventilating a seat. Themethod includes providing a thermoelectric device (TED) and conditioningair with the TED to provide heating or cooling and communicating thatconditioned air through an insert with either pushing or pulling thecondition air through the insert.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 shows an exploded view of a first embodiment of the insert.

FIG. 2 shows a schematic view of a system including the first embodimentof the insert.

FIG. 3 shows an exploded view of a second embodiment of the insert.

FIG. 4 shows a schematic view of a system including the secondembodiment of the insert.

FIG. 5 shows an exploded view of a third embodiment of the insert.

FIG. 6 shows a schematic view of a system including the third embodimentof the insert.

FIG. 7 shows an exploded view of a fourth embodiment of the insert.

FIG. 8 shows a schematic view of a system including the fourthembodiment of the insert.

DETAILED DESCRIPTION

The present invention includes an insert suitable for placement withinor on a seat to provide heating, cooling, ventilation or a combinationthereof to a seat occupant. The insert will include at least one layer,but preferably includes multiple (e.g. three) layers and each of thelayers may be a monolayer or a plurality of layers (e.g. a laminate).The plurality of layers need not be attached to each other butpreferably are. More preferably, the layers are attached to each otherat least at their edges to form an edge-sealed bag. The layers of theinsert are typically co-extensive, although partial layers that are notco-extensive with the other layers or the insert may be suitable incertain instances.

The insert and the layers that make up the insert typically have a seatportion and an extension. As the name suggests, the seat portiongenerally is the area of the insert that will provide heating, cooling,ventilation or combinations thereof to the area of the seat where theseat occupant resides. The extension permits components of a systemincluding the insert to be remote from the seat portion. This allows thecomponents to be conveniently located so that they do not interfere withthe comfort of the seat. While typically the extension is located at theback of the seat, it may be located on either side, in the front of theseat or absent altogether. Multiple extensions may also be used on aninsert.

Typically, the insert is supported by a seat cushion or backrestcushion. The seat cushion or backrest cushion may include one or moreducts that extend partially or completely through the cushion, or thecushions may be free of ducts that extend through the cushion. Apreferred cushion is a molded plastic foam, which is preferably free ofa molded or cut-out fluid distribution ducting network, but may beadapted with a trench or opening for passing the extension from one sideof the cushion to the another side. The seat cushion and/or backrestcushion may in turn be supported by a seat frame. Multiple inserts maybe used on a single seat or backrest cushion, where inserts mayaccomplish the same or different functions (e.g. one insert may onlycool, while another insert may both heat and cool).

One or more different kinds of layers may be used to make up the insert.For example, the insert may include one or more spacers to provide anopen space within the insert. One or more flow control layers may beincluded to provide selective flow of fluid between one or more layersof the insert, between the insert and the rest of the seat, or betweenthe insert and the ambient. One or more fluid barriers may be included.Other optional layers include layers that include heaters, coolers, oneor more additional spacers, one or more covering layers, and/or one ormore layers that assist in the manufacture of the insert.

The spacer may be any structure, material or combination of materialsand/or structures that permits fluid flow through the material whilealso providing a measure of support for a seat occupant. The spacersshould not collapse under the weight of a seat occupant and maintain thefluid communication through the spacer. As one example, the spacer mayinclude rubber, foam plastic or the like. In one aspect, the spacer mayinclude a reticulated foam or springs.

The spacer may include a plurality of members or fibers that arepreferably spaced apart from each other to provide open spacetherebetween while still being close enough together to provide cushionand support. One preferred spacer is formed of polymeric (e.g.,polyester) strand material that is interwoven to provide opposinghoneycomb structures (e.g., fabric panels), which are interconnected byseveral additional polymeric strand materials to provide open spacebetween the structures while still providing cushion and support. As anexample, one preferred material is sold under the tradename 3MESH® andis commercially available from Müller Textil GmbH, Germany or MüllerTextiles, Inc., R.I., USA.

Another preferred spacer is formed of a polymeric material in a helixheld between two sheets of material. Preferably, the helix is oblong inorder to provide increased area on the helix for attachment of the helixto the sheets of material. The helix may be tightly wound such thatadjacent courses of the helix touch or loosely wound such that there isno touching of adjacent courses of the helix. Typically, multiplehelices are placed adjacent (abutting or otherwise) to one another inorder to form a spacer. Exemplary helical material is discussed ininternational applications PCT/DE04/000540 and PCT/DE04/000541, bothfiles Mar. 17, 2004, both of which are incorporated by references.

Another preferred spacer material is a grooved material. The groovedmaterial includes a plurality of hills and valleys, where the hills havethrough holes. The grooved material may include any suitable materialsuch as a molded or shaped foam or plastic. The flow holes may be madebefore, at the same time, or after the hills and valleys.

Combinations of the above described materials may be used to afford aspacer.

The flow control layer is typically formed of a plastic or polymericmaterial that softens or melts upon exposure to heat to assist itsadherence to one or more other layers of the insert. Alternatively, theflow control layer may be formed of fabrics, woven materials (e.g.,Goretex® or microfibers), nylon, closed pore foam or other the like.Preferably, the flow control layer is at least partially impermeable tofluids and particularly to air, except at a plurality of through holes.The layer need not be substantially impermeable to any fluid or air.Exemplary through holes include ports (e.g. inlets and/or outlets),typically located in the extension, and flow holes, typically located inthe seat portion.

Dimensionally, for a flow control layer, it is preferable for the filmthickness to be about 0.1 mm to about 2.0 mm thick and more preferablyabout 0.7 mm to about 1.0 mm thick. Of course, it is contemplated thatthe flow control layer may have a variable thickness and may be outsideof the aforementioned ranges.

The fluid barrier may be similar to the flow control layer and mayinclude the same or different materials as the flow control layer.Preferably, the fluid barrier has similar composition and dimensions asthe flow control layer. Like the flow control layer, the fluid barriermay include one or more ports, typically on the extension of the insert.Unlike the flow control layer, the fluid barrier does not comprise flowholes. Also like the flow control layer, the fluid barrier is at leastpartially impermeable to fluids and particularly to air, except at theports. The fluid barrier need not be substantially impermeable to anyfluid or air.

The ports and flow holes generally provide fluid communication acrossthe fluid barriers and the flow control layers. The flow holes aregenerally located on the seat portion of the insert. The pattern of theflow holes on each flow control layer may be the same or different. Inone preferred layout, the size of the flow holes varies in a gradientacross the seat portion of the insert. Typically, the flow holes will belarger near the front of the seat as compared to the back of the seat;however, this is not necessarily the case. By creating a gradient ofsize in this way, fluid flow through the flow control layer at variouslocations may be selected. In another preferred layout, the flow holesroughly correspond to the area of the seat where an occupant would makecontact with the seat.

Exemplary optional layers include those having a heater. Variousdifferent types of heaters are suitable for incorporation into a carseat and it is contemplated that any of such heaters may be incorporatedinto the inserts of the present invention. Such heaters typicallyincorporate flexible, electrical heating elements that are preferablythin, flat, non-obtrusive or a combination thereof. As examples, alay-wire heater, a carbon fiber heater, a positive thermal coefficient(PTC) heater, a thermoelectric heater or the like, which are typicallysupported with a backing (e.g., a cloth or fabric type backing) may beused within the insert. In a preferred embodiment, the heater is acarbon fiber type heater with a backing (e.g., a non-woven layer). Oneexemplary preferred heater is sold under the tradename CARBOTEX® andcommercially available from W.E.T. Automotive Systems, Inc. in Germanyand/or FTG Fraser-Technik GmbH. An example of such a heater is disclosedin U.S. Pat. No. 6,064,037, issued May 16, 2000, herein expresslyincorporated by reference for all purposes. A combination heater/coolerin the form of a flexible sheet of TEDs may be a suitable optionallayer. Flexible sheet TEDs include those discussed in U.S. Pat. No.6,700,052, which is incorporated by reference. Other coolers mayincludes those described in U.S. provisional application 60/505,806,filed Sep. 25, 2003, which is incorporated by reference.

The optional additional spacer may be the same or different material asused for spacers in other parts of the insert. A preferred optionaladditional spacer includes a reticulated foam.

Suitable optional covering layers include seat covers that are part ofthe insert or separate from the insert, but generally separate theinsert from the seat occupant. The seat cover may be any suitablematerial, including but not limited to at least one synthetic material,natural material (e.g., wool, leather or otherwise), or combinationthereof. In one embodiment the seat cover includes perforations over atleast a portion of the seating surface through which air or other fluidmay pass. In another embodiment the cover is substantially free ofperforations. For example, perforated or non-perforated leather may beused to separate the seat occupant from the insert, while a fleecematerial may be used as part of the insert to increase moisture wickingor otherwise provide a protective layer.

The additional spacer and the seat cover may have an area that isco-extensive with the insert or they may have areas that are greater orlesser than that of the insert.

One or more adhesive layers may be used to assist in the assembly of theinserts. The adhesive layers are preferably formed of a hot meltadhesive although this is not necessarily required. The adhesive may beprovided as a web or otherwise and may be continuous or non continuous(e.g., may be applied in drops, dabs or the like). The adhesivesub-layers may include polyamides, polyesters, elastomers, urethanes,olefin polymers or a combination thereof. Moreover, the adhesives may beformulated as desired for particular processing parameters orconditions. Preferably, the adhesive sub-layers are substantially freeof anti-blocking solutions, blowing additives, process contaminants orthe like which might interfere with adhesive performance. As an example,one suitable hot melt adhesive is commercially available as a non-wovenweb under the tradename SPUNFAB® from Spunfab, Ltd. 175 Muffin Lane,Cuyahoga Falls, Ohio 44223.

The insert of the present invention may be a separate unit that isassembled in a space between a seat cushion and the seat cover,integrally formed in the seat cushion, integrally formed in the seatcover, or any combination thereof.

In addition to the insert, the present invention includes a system thatprovides heating, cooling, ventilation or combinations thereof. Thesystem has an insert and one or more different components thatfacilitate the operation of the insert. For example, the system mayinclude a fan, a fluid conditioning device, one or more attachmentcomponents, one or more valves, one or more sensors and/or one or morecontrols. In addition, one or more conduits may be used to provide fluidcommunication between components of the system such as between the fanand the insert or between the insert and the fluid conditioning device.

The fan provides motive force to move air (whether conditioned, ambient,pushed, pulled and combinations thereof) through the insert. The fan maybe used to push air to the insert or pull air from the insert. The fanmay also be used to both push and pull air. For example, at least twosets of fan blades (e.g. with vanes that are opposite in direction) thatshare a common axis and form a binary fan that is able to both push andpull air. Multiple fans may also be used. The fan may also include anannular inlet, although fan that are free of annular inlets are alsocontemplated. Included in the definition of fan are impellers (includingbidirectional impellers), blowers, or the like. The fan also refers todevices that provide motive force to move other fluids (e.g. liquids)through the insert. The fan may provide a steady fluid flow, a pulsatingfluid flow, an oscillating fluid flow, or the like.

The fluid conditioning device may be any device that heats or coolsfluid. The device may be a combination of devices where one componentprovides heating and another component provides cooling. Preferably, onedevice or system provides both heating and cooling. The device may be anexternal device such as the HVAC system in the building or vehicle wherethe seat is located or an internal device meaning that the device is notconnected (other than to a power supply) to the building or vehiclewhere the seat is located. In addition to providing temperatureconditioning the fluid conditioning device may also dehumidify the fluid(e.g. air).

Preferably, the fluid conditioning device is a self contained or solidstate device that both cools and heats air. The most preferred device isa peltier or thermoelectric device (TED). TEDs are commerciallyavailable devices that provide solid state heating and cooling bypassing electricity through the device. TEDs include a waste side and anactive side, which are relative designations depending whether warm orcool temperature conditioned air is desired. Any supplier of TEDs wouldbe able to provide suitable devices for use in the present invention,with TEDs from Tellurex (Telluride, CO) being preferred. The TED may becombined with any useful heat dissipation device; e.g. heat sinks, heatexchangers, fans, heat pipes or the like.

The attachment component is a frame member that preferably defines alocation for the attachment of the fan, fluid conditioning device, aconduit or other component to the insert. It is contemplated that theframe member may be in a variety of configurations (e.g., annular,rectangular, square, polygonal or otherwise) and may be formed of avariety of preferably rigid or semi-rigid materials (e.g. metal, plasticor the like). In some aspects, the attachment component also helpsdefine a port. In one preferred embodiment, the attachment componentcooperates with structures and/or materials (e.g. snap fit fasteners) onthe fan, the fluid conditioning device or other components to connectthe device or component to the attachment component.

One or more valves may be used to redirect fluid flow through the systemto make use of unused energy (i.e. the fluid is hotter than ambient) orenergy capacity (i.e. the fluid is colder than ambient) in the fluid.For example, the valves may be used to vent fluid to ambient to disposeof un-needed energy stored in the fluid. The valves may also be used toredirect fluid to components of the system (e.g. the fluid conditioningdevice) to either warm or cool such components. In addition, a valve maybe used to optionally recirculate fluid within system to create a closedor partially closed system.

A variety of sensors may be included in the system such as temperaturesensors, humidity sensors, current sensors, occupant detection sensor,weight sensors or the like. Sensors may be placed throughout the system.For example, temperature sensors may be place within the spacer, betweenspacers, between the spacer and any additionally optional layer (e.g.reticulated foam or seat cover), near the fluid conditioning device,near the fan, and combinations thereof.

One or more controllers may be used to receive inputs from the sensorsor a used control device, to issue instructions to the fan and fluidconditioning device, and/or to otherwise coordinate the operation of thesystem.

The embodiments of the inserts and systems discussed below utilize airas the temperature conditioned fluid communicated through the insertand/or system. It should be understood, however, that other gas and/orliquid fluid may also be utilized in these embodiments.

As seen in FIG. 1, the first embodiment of the insert 10 generallyincludes a seat portion 12 and an extension 14. The insert also includesa first flow control layer 16, a first spacer 18, a second flow controllayer 20, a second spacer 22 and a first fluid barrier 24. Here, thespacers comprise a polymeric strand material. In a preferred embodiment,these layers are sealed together at least at their edges to form an edgesealed bag.

Both the first flow control layer 16 and the first fluid barrier 24include at least one port 26 and 28, respectively. The ports aregenerally located on the extension of the insert and provide access tothe spacers. Instead of in the first fluid barrier, the port 28 may belocated laterally to the second spacer layer. In this aspect, the portis defined by the extensions of the second flow control layer and thefirst fluid barrier. In another aspect, the port may be located in thesecond flow control layer 20. Here, a partial fluid barrier 30 (shown inphantom) would be needed to separate the neck of the second flow controllayer 20 from the neck of the first spacer 18.

The flow control layers include a plurality of flow holes 32. The flowholes are generally located on the seat portion of the insert. Thepattern of the flow holes on each flow control layer may be the same ordifferent.

In another aspect, the first flow control layer may be replaced with asecond fluid barrier with a port on the extension. This provides aninsert that would not blow or draw air to or from the seat occupant. Inyet another aspect, the first flow control layer may be replaced with acombination of reticulated foam on the seat portion and a fluid barrieron the extension. The fluid barrier would include a port.

In a system including the insert of the first embodiment, the fan isattached to the insert at one of the ports. Alternatively, a conduitconnects a fan to the insert at either of the two ports. Such attachmentmay be facilitated by an attachment component. The fan may be configuredto either pull air out of the insert or push air into the insert.

The system including the first embodiment of the insert also preferablyincludes an fluid conditioning device in the form of a TED. The TED maybe located remote from the insert and the fan, but this is notnecessarily so. Indeed, the TED may preferably be placed adjacent to theinsert or attached to the insert with an attachment component. The TEDis preferably positioned such that air flow across both the waste andactive sides of the TED is possible through the use of a single fan. Inaddition, the TED may be placed relative to the fan such thatconditioned air from the active side of the TED is either pushed to thespacers or pulled from the spacers. Conduits may be used to achieve thedesired air flow.

In a preferred embodiment, as shown schematically in FIG. 2, the insert10 includes two flow control layers 16 and 20 and the fan 34 pulls airacross the active side 36 of a TED 38 and through the spacers 18, 22,while also pulling air across the waste side 40 of the TED. This aspectis shown with an optional additional spacer 42. The air flow isindicated schematically by the arrows in FIG. 2. In the alternative, thefan may push air across the waste side. In one preferred embodiment, theactive side of the TED is cooling the air being drawn across it by thefan, while the waste side of the TED is having heat evacuated from it bythe fan. The temperature conditioned air is routed through the spacersto provide the seat occupant with a cooling sensation.

In one aspect, the second flow control layer permits ambient air (i.e.air not conditioned by the fluid conditioning device) from near the seatoccupant to be drawn by fan to provide additional ventilation andcooling. Such a configuration is shown in FIG. 2, where the arrowsindicate that air is drawn through the top of the insert. In anotheraspect, a second fluid barrier is used in place of the first flowcontrol layer, which prevents ambient from being drawn from near theseat occupant.

As seen in FIG. 3, the second embodiment of the insert 100 is similar tothe first embodiment with the first spacer 102 including a groovedmaterial 104. The use of the grooved material makes the use of the firstflow control layer 106 (shown in phantom) optional. The insert alsoincludes a second spacer 108 and a fluid barrier 110. The groovedmaterial 104 includes a plurality of hills 112 and valleys 114, thehills include a plurality of flow holes 116. In the aspect shown in FIG.3, the grooved material makes up only a portion of the first spacer andanother spacer material (e.g. polymeric strand material) makes up theremainder of the first spacer. Alternatively, the first spacer may becompletely made up of the grooved material. While generally parallelhills and valleys are preferred, other arrangement of hills and valleysmay also be suitable. Typically, when the first spacer is entirelygrooved material, the valleys will extend from the seat portion to theport area in the extension. In this aspect, the flow holes may only belocated on hills in the seat portion of the insert. In this embodiment,a partial fluid barrier 118 may be needed between the extensions of thespacers to facilitate air flow through the seat portions of the spacers.

Like the system including the first embodiment of the insert, the systemincluding the insert of the second embodiment makes similar use of a fanand TED. As described above, the fan and TED may be combined in avariety of ways in the system.

In a preferred embodiment of the system, as shown schematically in FIG.4, a fan 120 is positioned to draw air across the active side 122 of aTED 124 through the second spacer 108, through the flow holes 116, downthe valleys 114 toward the fan and across the waste side 126 of the TED,as shown by the arrows. Here, a fluid barrier may be used to prevent thefan from drawing ambient air from near the seat occupant. This aspect isshown with an optional additional spacer 128.

As seen in FIG. 5, in a third embodiment of the insert 200 generallyincludes a seat portion 202 and an extension 204. The insert alsoincludes a flow control layer 206, a spacer 208, and a fluid barrier210. A second fluid barrier may be substituted for the flow controllayer 206.

The spacer 208 includes a main portion 212 with a cutout 214 therein. Aninlay 216 is adapted to be received within the cutout 214. In analternate embodiment, the relative positions of the main portion and theinlay are reversed such that the inlay at least partially surrounds themain portion. This embodiment is similar to the fourth embodiment(discussed below) where the conduit comprises a spacer material

The main portion and the inlay may be the same or different materialsfrom each other and their materials are typically selected from thespacer materials discussed above.

When the inlay 216 is assembled with the main portion 212 (i.e. inlaidin the main portion) there is a fluid barrier 218 that at leastpartially creates a fluid-tight boundary that prevents fluidcommunication between the main portion 212 and the inlay 216 of thespacer.

Typically, when assembled, the inlay resides both in the extension andthe seat portion of the insert. While shown in FIG. 5 as beingun-branched, the inlay may take on a variety of branched shapes, such aY-shape where the arms of the Y reside in the seat portion while thetail resides in the extension of the insert. A “branches-on-branches”configuration may also be suitable. Generally, only one inlay ispreferred, but multiple inlays may be suitable.

The fluid barrier may located on or about the inlay, in the main portionor be a separate component from both the main portion and the inlay. Inone preferred aspect, the fluid barrier is included in the inlay.

The inlay includes a port 220 in the fluid barrier that provides fluidcommunication to the interior of the inlay. The port is typicallylocated in area of the inlay that resided on the neck of the insert. Theinlay also preferably includes a plurality of flow holes 222 in area ofthe inlay that resides in the seat portion of the insert. These flowholes may be aligned parallel to the plane of the insert, normal to theplane of the insert, or at some other angle. The flow control sheetincludes a port 223 aligned with the main portion and that providesfluid communication to the interior of the main portion.

In one aspect, the inlay may comprise a strand material, a groovedmaterial or a reticulated foam material. With the grooved material itmay not be necessary to utilize the fluid barrier on or around theinlay.

Like the systems including the first and second embodiments of theinsert, the system including the insert of the third embodiment makessimilar use of a fan and TED. As described above, the fan and TED may becombined in a variety of ways in the system.

In a preferred embodiment of the system, as shown schematically in FIG.6, the insert 200 includes a fan 224 that pulls air across the activeside 226 of a TED 228 and through the inlay 216 to the main portion 212or to an optional additional spacer 230 via flow holes. The fan alsopushes air across the waste side 232 of the TED. In the alternative, thefan may pull air across the waste side. In one preferred embodiment, theactive side of the TED is cooling the air being drawn across it by thefan, while the waste side of the TED is having heat evacuated from it bythe fan. The temperature conditioned air is routed through the inlay andmain portions of the spacer to provide the seat occupant with a coolingsensation.

As seen in FIG. 7, in a fourth embodiment of the insert 300 generallyincludes a seat portion 302 and an extension 304. The insert alsoincludes a flow control layer 306, a spacer 308, a fluid barrier 310 andat least one conduit 312. Preferably, a plurality of conduits is used.In one embodiment, a second fluid barrier may be substituted for theflow control layer 306.

The conduit provides fluid communication to or from the seat portion ofthe insert. Preferably, the conduit is generally located along the edgeof the seat portion or the extensions of the insert. In the alternative,the conduit may extend into the seat portion of the insert.

The conduit comprises one or more flow holes 314 located on the seatportion of the conduit. The flow holes may have one or more directions,i.e. generally normal to the place of the insert, generally in the sameplane as the plane of the insert, or any angle in between. The conduitmay be held within the insert (whether the insert is a sealed bag insertor not), attached to the exterior of the insert or formed as part of theinsert. In a preferred embodiment, the conduit is located underneath theflow control layer and in the plane of the insert. As seen in the FIG.8, the conduit may be located above the flow control layer.

The conduit is preferably made of a flexible tubing material that isdistinct from the material of the spacer, although this is notnecessarily the case. Suitable flexible tubing material includes tubingwith wall thicknesses ranges from about {fraction (1/64)} in to about 1in or more. The material of suitable tubing may be selected to providelow thermal capacity, meaning that tubing does not insulate well. Theconduit may also comprise spacer material that is sectioned from theinsert by a fluid-tight barrier. While generally part of the insert, theconduit may be used to replace other components of a seat (e.g. as afront or side bolster) or may be used augment other components of a seat(e.g. the additional spacer layer).

Like the systems including the other embodiments of the insert, thesystem including the insert of the fourth embodiment makes similar useof a fan and TED. As described above, the fan and TED may be combined ina variety of ways in the system. A port 316 for the fan is generallylocated on the extension of the insert, while the TED is preferablyco-located with the extension of the insert; more preferably it isattached to extension.

In a preferred embodiment of the system, as shown schematically in FIG.8, the insert 300 includes a fan 318 that pulls air through the spacer308 and/or through the additional spacer 320 from the flow holes of theconduit 312. The fan pulls the air across the active side 322 of a TED324 through a manifold to the flow holes of the conduit. The fan alsopushes air across the waste side 326 of the TED. In the alternative, asecond fan is used to push air across the active side of the TED throughthe manifold to the flow holes of the conduit.

In one preferred embodiment, the active side of the TED is cooling theair being drawn across it by the fan, while the waste side of the TED ishaving heat evacuated from it by the fan. The temperature conditionedair is routed through the spacer to provide the seat occupant with acooling sensation.

Depending on the location of the conduit and the flow holes, thetemperature conditioned air may flow directly to or from the conduit tothe spacer. Alternately, the air may flow through another materialbetween the conduit and the spacer. In this way, the temperatureconditioned air is pulled (and/or pushed) across the surface of theinsert. For example, the air may flow through or over any of theoptional layers discussed above such as an additional spacer (e.g.reticulated foam) or a covering (e.g. perforated leather).

In a preferred embodiment, the temperature conditioned air flows intothe additional spacer and ambient air flows through the seat cover intothe additional spacer, where the air mixes. The mixed air flows into thespacer material of the insert because of the pulling of the fan. Inanother preferred embodiment, the mixed air does not flow. This may beachieved by through selection of the size and power of the fan(s) usedin the system. In a one fan system, the fan should produce a negativepressure in the additional spacer. In a two or more fan system, any fansthat push air through the manifold to the flow holes of the conduitshould produce a positive pressure that is less than the negativepressure produced by the fan that pulls air through the insert.

In one optional embodiment, a valve (not shown) is utilized to redirecttemperature conditioned air before it flows through the spacer. Suchredirected air may be vented to ambient because the insert has reachedthe desired temperature. Such redirected air may also be shunted to thewaste side of the TED to help dissipate waste energy.

In another optional embodiment, a valve is utilized to recirculatetemperature conditioned air after it has flowed through the spacer. Suchrecirculated air may have a temperature that is closer to the desiredtemperature than that of ambient air. For example, when the TED is inthe cooling mode, the recirculated air may be cooler than ambient air.Thus, it would be more efficient to cool the recirculated air to thedesired temperature than it would be to cool the ambient air.

In another embodiment, the present invention comprises a ventilated seata perforated seating surface that supports a seat occupant and a mixingregion that is located under the seating surface where ambient air iscombined with a cooled fluid. A fan may be use to bring ambient air intothe mixing region. The fan may also function to bring the cooled fluidto the mixing region or to remove the mixed ambient air and cooled fluidfrom the mixing region. As discussed above, a fluid conditioning devicemay be used to modify (e.g. reduce) the temperature of the fluid.

In one embodiment, it is contemplated that the control system isemployed to automatically change the power provided to the TED when acertain temperature has been reached or after a certain period of time.Less preferably, though also possible, the system automatically changesthe power based upon a combination of both a sensed temperature and acertain period of time. In this regard, one system of the presentinvention preferably automatically regulates only one of the amount ofpower directed to the TED or the operating speed of the fan or the liketo achieve the desired cooling temperature. However, one embodiment alsocontemplates the automatic regulation of both the amount of powerdirected to the TED and the operating speed of the fan. It is preferredthat the operation of the system of the present invention is doneindependent of any signal from an occupant detection senso, if any.However, it is possible that an occupant detection sensor is employed incommunication with a control system for automatically operating thesystem upon detection of the presence of a user.

The present invention also relates to the methods of providing heating,cooling, ventilation or combination thereof. One method includes pullingair across an active side of a TED, through one or more spacers andacross a waste side of the TED. Another method includes pulling airacross an active side of a TED, through an inlay, through a main portionof a spacer, and across a waste side of the TED. Yet another methodincludes pulling air across an active side of a TED, through a conduit,through a spacer and across a waste side of the TED. In all of thesemethods, the air may be pushed across the waste side of the TED.Furthermore, instead of generally pulling the air, pushing the air maybe utilized. It will be recognized that the in the above methods otherfluid conditioning devices besides TEDs may be used and that fluidsother than air may be moved by the fan.

In another embodiment, the method comprises drawing ambient air througha seating surface of a transportation vehicle seat into a mixing regionof the seat. In the mixing area, the ambient air is mixed with aircooled by a thermoelectric device and provided to the mixing region. Inone embodiment, the pressure in the mixing region below the ambientpressure so that substantially all of the resulting mixture does notpass through the seating surface. In another embodiment, cooled air isblown into the mixing region while substantially all the resultingmixture is kept from passing through the seating surface. In eitherembodiment, the resulting mixture is removed from the mixing region. Inone embodiment, the mixing region is located within an insert. Inanother embodiment, the mixing region is disposed between an insert anda seating surface.

In a preferred embodiment, the present invention provides cooling fromabove about 100° C. and more preferably provides cooling from about 80°C. Also, the present invention provides cooling to below about 37° C.,and more preferably to below about 27° C., and most preferably belowabout 25° C. These temperatures may refer to air temperature within theinsert, anywhere within the system or the temperature at or near theseat surface. In one preferred embodiment, the present inventionprovides cooling at a rate of greater than about 5° C./min, greater thanabout 10° C./min, greater than about 15° C./min and greater than about20° C./min, greater than about 25° C./min and greater than about 35°C./min.

Preferably, the insert and the system may be included in a seat used ina transportation vehicle (e.g. an automotive vehicle seat); however, theinsert and system may be used in a variety of other seats such as deskchairs, lounge chairs, or the like.

Generally, for forming an insert according to the present invention, itis contemplated that the various layers of the insert as described abovemay be combined in a variety of sequences and according to a variety ofprotocols and techniques. Thus, the order in which the various layersand sub-layers are combined and the techniques of combining should notin any way limit the present invention unless such order or techniquesis specifically claimed. Moreover, it is also contemplated that theremay be greater or fewer layers and that each layer may include greateror fewer sub-layers.

In general, a lamination process is preferred to assemble the layers ofthe inserts. U.S. patent application Ser. No. 10/434,890, filed on May9, 2003, hereby incorporated by reference, includes a discussion of onesuitable technique for assembling the layers of inserts according to thepresent invention.

For assembly of the insert or system to a seat, the insert is preferablysecured (e.g., sewn, adhered or otherwise attached) to a portion of theseat such as the cover (e.g., a perforated leather cover) or to a seator backrest cushion (e.g., foam) of the seat. In one embodiment, theinsert is first secured to a seat cover and then the seat cover issecured to the seat. For example, the insert may be joined to seat coverat the edges of the insert or it may be joined to the seat cover atlocations other than along the edges of the insert.

In another embodiment, a seat cover may be configured to include apocket for receiving the insert. Alternatively, it is contemplated thathook and loop fasteners may be utilized to attach the insert to portions(e.g., the cover, frame, seat cushion or backrest cushion) of the seat.Other techniques may be used to assemble the insert to the seat such assewing, adhesives, snap-fit fasteners or locating pins. Furthermore, theinsert may be attached to other components of the seat such as the seatframe.

By packaging the components of the system substantially entirely withina seat of the present invention, rather than external thereof, it ispossible to realize various advantages, such as ease of manufacturingand assembly. For example, it is possible to assemble all of thefunctional components at a remote assembly site, and thereaftertransport a seat to an automotive assembly line, where the seat ismerely mounted to the body in white and connected to the vehicleelectrical system. In contrast, other systems might rely upon a coolingdevice that is located external of a seat to provide cooled air to theseat. Though such systems are within the scope of certain embodiments ofthe present invention, they are less preferred.

It will be further appreciated that functions or structures of aplurality of components or steps may be combined into a single componentor step, or the functions or structures of one-step or component may besplit among plural steps or components. The present inventioncontemplates all of these combinations. Unless stated otherwise,dimensions and geometries of the various structures depicted herein arenot intended to be restrictive of the invention, and other dimensions orgeometries are possible. Plural structural components or steps can beprovided by a single integrated structure or step. Alternatively, asingle integrated structure or step might be divided into separateplural components or steps. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the invention. The scope of the inventionshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes.

1. A method of assembling a seat, comprising: locating an insert betweena seat cushion or a backrest cushion and a seat cover; fluidlyconnecting a fan to the insert; and fluidly connecting a fluidconditioning device to the insert, wherein the fan and the fluidconditioning device are fluidly connected to each other through theinsert.
 2. The method of claim 1, further comprising locating anadditional spacer between the insert and the seat cover.
 3. The methodof claim 1, wherein the locating step comprises attaching the insert tothe seat cushion of the backrest cushion.
 4. The method of claim 1,wherein the locating step comprises attaching the insert to the seatcover.
 5. The method of claim 1, wherein the fluidly connecting the fanstep comprises attaching the fan to an attachment component of theinsert.
 6. The method of claim 1, wherein the fluidly connecting thefluid conditioning device step comprises fluidly connecting athermoelectric device (TED) to the insert.
 7. The method of claim 6,wherein the fluidly connecting the fluid conditioning device stepcomprises attaching the TED to an attachment component of the insert. 8.The method of claim 7, further comprising fluidly connecting a secondfan to the TED.
 9. The method of claim 1, wherein the locating stepoccurs before the connecting the fan step or the connecting the fluidconditioning device step.
 10. A method of making an insert, comprising:laminating together a plurality of layers comprising at least a flowcontrol layer, a spacer, and a fluid barrier layer and comprising atleast one of the following: a second spacer, a second flow controllayer, a spacer with an inlay, and combinations thereof.
 11. The methodof claim 11, wherein the laminating step further comprises applying oneor more adhesives to the plurality of layers.
 12. A method ofventilating a seat, comprising: providing a thermoelectric device (TED)fluidly connected to an insert; temperature conditioning air with theTED; and pulling air conditioned by the TED through the insert.
 13. Themethod of claim 12, further comprising pulling ambient air through theinsert.
 14. The method of claim 12, wherein the pulling step does notinclude pulling ambient air through a seat cover.
 15. The method ofclaim 14, wherein the seat cover is a non-perforated material.
 16. Themethod of claim 12, wherein the pulling step comprises mixing airconditioned by the TED and ambient air in an additional spacer.
 17. Themethod of claim 12, further comprising pulling air conditioned by theTED through a conduit.
 18. The method of claim 12, further comprisingpulling air conditioned by the TED through an inlay.
 19. The method ofclaim 12, further comprising pulling air conditioned by the TED throughan insert comprising at least two spacers.
 20. The method of claim 12,further comprising pushing air through the insert.
 21. The method ofclaim 20, wherein the pulling step comprises utilizing a first fan andthe pushing step comprises utilizing a second fan pushing air across anactive side of a TED.
 22. The method of claim 12, further comprisingventing or recirculating air through the use of a valve.
 23. The methodof claim 12, further comprising one or more of: sensing a temperature ofambient air, temperature conditioned air, recirculated air, theadditional spacer layer, and combinations thereof, controlling theoperation of the fan, the TED, and combinations thereof based on time ortemperature; dehumidifying the air; cooling the air with the TED;heating the air with the TED; and combinations thereof.
 24. A method forcooling a seat of a transportation vehicle, comprising: drawing ambientair through a surface of a transportation vehicle seat into a mixingregion of the seat; mixing the drawn ambient air with a cooled fluidprovided to the mixing region; and removing the resulting mixture fromthe mixing region.
 25. The method of claim 24, further comprising thestep of providing cooled fluid through the use of a thermoelectricdevice.
 26. The method of claim 25, further comprising maintaining thepressure in the mixing region below the ambient pressure so thatsubstantially all of the resulting mixture does not pass through theseating surface.
 27. The method of claim 25, wherein the cooled fluid isprovided by blowing cooled air into the mixing region while preventingsubstantially all of the resulting mixture from passing through theseating surface.
 28. The method of claim 24, wherein the transportationvehicle is an automotive vehicle, and the cooled fluid is air.
 29. Themethod of claim 28, further comprising the step of cooling air bypassage of the air through a heat exchanger and advancing the air to themixing region.
 30. The method of claim 29, wherein the heat exchangerincludes a thermoelectric device and the air is advanced by a fan. 31.The method of claim 24, wherein the mixing region is disposed at leastpartially within an insert.
 32. The method of claim 24, wherein themixing region is disposed at least partially between an insert and theseating surface.
 33. The method of claim 32, further comprising definingthe mixing region in a space of the insert that has a plurality of flowholes through which the ambient air is drawn.
 34. The method of claim24, wherein the mixing region is enclosed within an insert.
 35. Themethod of claim 34, further comprising defining the mixing region in aspace of the insert that has a plurality of flow holes through which theambient air is drawn.
 36. The method of claim 35 wherein the insert isattached in fluid communication with the fan.
 37. The method of claim36, wherein the fan and the thermoelectric device are secured internallywithin the seat.
 38. The method of claim 36, wherein the seat comprisesa seat cover disposed over the insert for defining a seating surface.39. The method of claim 38, wherein the seat cover is made of a materialselected from a synthetic material, a natural material or a combinationthereof, and the cover is selected from a woven material, an unwovenmaterial, a perforated material, an impermeable material, or anycombination thereof, and the seat further comprises at least one foamseat or backrest cushion.
 40. The method of claim 39, wherein the cooledfluid is provided by blowing cooled air into the mixing region whilepreventing substantially all of the resulting mixture from passingthrough the seating surface.
 41. The method of claim 39, furthercomprising maintaining the pressure in the mixing region below theambient pressure so that substantially all of the resulting mixture doesnot pass through the seating surface.
 42. The method of claim 39,further comprising the step of exhausting at least a portion of theresulting mixture to ambient air.
 43. The method of claim 40, furthercomprising the step of re-circulating at least a portion of the removedresulting mixture back into the mixing region.
 44. The method of claim40, further comprising maintaining the pressure in the mixing regionbelow the ambient pressure so that substantially all of the resultingmixture does not pass through the seating surface.
 45. The method ofclaim 40, wherein the cooled fluid is provided by blowing cooled airinto the mixing region while preventing substantially all of theresulting mixture from passing through the seating surface.
 46. Themethod of claim 24, wherein the seating surface includes a cover made ofa material selected from a synthetic material, a natural material or acombination thereof, and the cover is selected from a woven material, anunwoven material, a perforated material, an impermeable material, or anycombination thereof, and the seat further comprises a foam seat cushion.47. The method of claim 24, further comprising the step of exhausting atleast a portion of the resulting mixture to ambient air.
 48. The methodof claim 47, further comprising the step of re-circulating at least aportion of the removed resulting mixture back into the mixing region.49. The method of claim 24, further comprising maintaining the pressurein the mixing region below the ambient pressure so that the mixturesubstantially all of the resulting mixture does not pass through theseating surface.
 50. The method of claim 24, wherein the cooled fluid isprovided by blowing cooled air into the mixing region while preventingsubstantially all of the resulting mixture from passing through theseating surface.